Removal And Installation
FUEL TANK
Removal and Installation
REMOVAL
WARNING:
Read "General Precautions" before working on the fuel system.
Refer to "General Precaution" General Precautions.
1.Disconnect the battery negative terminal. Refer to "Removal and Installation (Battery)" Removal And Installation.
2.Check the fuel level with the vehicle on a level surface. If the fuel gauge indicates more than the level as shown (1/2 full), drain the fuel from the fuel tank until the fuel gauge indicates a level at or below as shown (1/2 full).
- In case the fuel pump does not operate, use the following procedure.
a.Insert fuel tubing of less than 25 mm (0.98 in) diameter into the fuel filler tube through the fuel filler opening to drain fuel from the fuel filler tube.
b.Disconnect the fuel filler hose from the fuel filler tube.
c.Insert fuel tubing into the fuel tank through the fuel filler hose to drain fuel from the fuel tank.
- As a guide, if the fuel tank is full the fuel level reaches or is less than the level on the fuel gauge as shown, when approximately 34 (9 US gal, 7 1/2 Imp gal) of fuel is drained from a full fuel tank.
3.Open the fuel filler cap to release the pressure inside the fuel tank.
4.Release fuel pressure from fuel line. Refer to "Work Procedure" Testing and Inspection (QR25DE), "Work Procedure" Testing and Inspection (VQ35DE).
5.Remove rear seat cushion. Refer to "Removal and Installation Seat Assembly" Seat Assembly.
6.Turn the four retainers (A) 90� in a clockwise direction and remove the fuel pump inspection hole cover.
White arrow indicates : Front
7.Disconnect the fuel level sensor, fuel filter, and fuel pump assembly harness connector (C), EVAP hose quick connector (A), and fuel feed hose (B) quick connector.
White arrow indicates : Front
a.Disconnect the quick connectors as follows:
- Hold the sides of the connector, push in tabs and pull out the tube.
- If the connector and the tube are stuck together, push and pull several times until they start to move. Then disconnect them by pulling.
CAUTION:
- The tube can be removed when the tabs are completely depressed. Do not twist it more than necessary.
- Do not use any tools to remove the quick connector.
- Keep the resin tube away from heat. Be especially careful when welding near the tube.
- Prevent acid liquid such as battery electrolyte, from getting on the resin tube.
- Do not bend or twist the tube during installation and removal.
- Only when the tube is replaced, remove the remaining retainer on the tube or fuel level sensor, fuel filter, and fuel pump assembly.
- When the tube or fuel level sensor, fuel filter, and fuel pump assembly is replaced, also replace the retainer with a new one (green colored retainer).
- To keep the connecting portion clean and to avoid damage and foreign materials, cover them completely with plastic bags or something similar.
8.Remove rear wheel and tire using power tool. Refer to "Adjustment" Adjustment.
9.Remove rear brake pads. Refer to "BRAKE PAD : Removal and Installation" Removal And Installation
10.Remove rear torque members and rear disc brake rotor.
11.Disconnect rear parking brake shoe, and remove rear cables from toggle lever. Refer to "Removal and Installation" Removal And Installation
12.Disconnect the 4 park brake rear cable mounting nuts (A) and position the rear park brake cables aside.
13.Remove the tunnel stay and center exhaust tube, without muffler(s). Refer to "Removal and Installation" Removal And Installation (QR25DE), "Removal and Installation" Removal And Installation (VQ35DE).
14.Remove the fuel tank protector.
15.Disconnect the fuel filler hose and the recirculation hose at the fuel tank side.
16.Disconnect the EVAP line at the canister.
17.Remove the EVAP canister filter bracket mounting bolt and position EVAP canister filter and EVAP canister filter mounting bracket aside.
18.Disconnect the fuel tank mounting straps while supporting the fuel tank with a suitable jack.
CAUTION:
Fuel tank may be in an unstable condition, due to the shape of the fuel tank bottom. Be sure to secure tank at all times.
19.Remove the fuel tank.
20.If replacing the fuel tank, remove the fuel level sensor, fuel filter and fuel pump assembly to transfer to the new fuel tank. Remove and discard the O-ring.
CAUTION:
- Discard the O-ring. Do not reuse the O-ring.
- Do not bend float arm during removal and installation.
INSTALLATION
Install in the reverse order of removal paying attention to the following.
- Before tightening the fuel tank mounting straps, temporarily install the filler hose and the recirculation hose.
Tighten all fuel tank mounting strap bolts to specification, then tighten the hose clamps.
- Connect the quick connector as follows:
- Check the connection for damage or any foreign materials.
- Align the connector with the tube, then insert the connector straight into the tube until a click is heard.
- After the tube is connected, make sure the connection is secure by performing the following checks:
- Pull on the tube and the connector to make sure they are securely connected.
- Visually confirm that the two retainer tabs are connected to the quick connector.
CAUTION:
Do not reuse O-ring.